Dehumidifier for High Airflow Rate Systems

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not applicable.

BACKGROUND

Heating, ventilation, and/or air conditioning (HVAC) systems may generally include one or more dehumidification components and/or systems, commonly referred to as a dehumidifier. Current dehumidifiers operate with an airstream that is either separate from a primary HVAC system or use only a portion of the airstream from the primary HVAC system. This may result in the dehumidifier running for extended periods that extend beyond a period for a cooling operation and/or running continuously in an attempt to achieve a target humidity. Accordingly, for current dehumidifiers to dehumidify an entire dwelling conditioned by the primary HVAC system, significant operating runtimes and/or significant operating costs may be incurred.

SUMMARY

In some embodiments of the disclosure, a heating, ventilation, and/or air conditioning (HVAC) system is disclosed as comprising: an indoor unit comprising a blower configured to generate an airflow; and a dehumidifier; wherein the entirety of the airflow generated by the blower passes through the dehumidifier.

In other embodiments of the disclosure, a heating, ventilation, and/or air conditioning (HVAC) system is disclosed as comprising: an indoor unit comprising a blower configured to generate an airflow; and a dehumidifier comprising an evaporator and a condenser; wherein at least a portion of the airflow passes through the evaporator of the dehumidifier, and wherein the entirety of the airflow passes through the condenser of the dehumidifier.

In yet other embodiments of the disclosure, a method of operating a heating, ventilation, and/or air conditioning (HVAC) system is disclosed as comprising: providing an indoor unit and a dehumidifier in an HVAC system; monitoring the humidity of a zone conditioned by the HVAC system; generating an airflow via a blower of the indoor unit; passing the entirety of the airflow through the dehumidifier; reducing the humidity of the airflow; and delivering the reduced humidity airflow to at least one zone conditioned by the HVAC system.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure and the advantages thereof, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description:

FIG. 1 is a schematic diagram of an HVAC system according to an embodiment of the disclosure;

FIG. 2 is a schematic diagram of an air circulation path of the HVAC system of FIG. 1 according to an embodiment of the disclosure;

FIG. 3 is a schematic diagram of an air circulation path of the HVAC system of FIG. 1 according to another embodiment of the disclosure;

FIG. 4 is a schematic diagram of an air circulation path of the HVAC system of FIG. 1 according to yet another embodiment of the disclosure;

FIG. 5 is a schematic diagram of a dehumidifier according to an embodiment of the disclosure;

FIG. 6 is a schematic diagram of a dehumidifier according to another embodiment of the disclosure; and

FIG. 7 is a flowchart of a method of operating an HVAC system according to an embodiment of the disclosure.

DETAILED DESCRIPTION

Referring now to FIG. 1, a simplified schematic diagram of an HVAC system 100 is shown according to an embodiment of the disclosure. HVAC system 100 generally comprises an indoor unit 102, an outdoor unit 104, and a system controller 106. The system controller 106 may generally control operation of the indoor unit 102 and/or the outdoor unit 104. As shown, the HVAC system 100 is a so-called heat pump system that may be selectively operated to implement one or more substantially closed thermodynamic refrigeration cycles to provide a cooling functionality and/or a heating functionality. Additionally, the HVAC system 100 may also comprise a dehumidifier 150.

Indoor unit 102 generally comprises an indoor heat exchanger 108, an indoor fan 110, and an indoor metering device 112. The indoor unit 102 may generally comprise at least one of a blow through air handling unit (indoor fan 110 disposed near air return) and a pull through air handling unit (indoor fan 110 disposed near air supply). In an embodiment, indoor heat exchanger 108 is a plate fin heat exchanger configured to allow heat exchange between refrigerant carried within internal tubing of the indoor heat exchanger 108 and fluids that contact the indoor heat exchanger 108 but that are kept segregated from the refrigerant. In other embodiments, indoor heat exchanger 108 may comprise a spine fin heat exchanger, a microchannel heat exchanger, or any other suitable type of heat exchanger.

In an embodiment, the indoor fan 110 is a centrifugal blower comprising a blower housing, a blower impeller at least partially disposed within the blower housing, and a blower motor configured to selectively rotate the blower impeller. In other embodiments, the indoor fan 110 may comprise a mixed-flow fan and/or any other suitable type of fan. The indoor fan 110 is configured as a modulating and/or variable speed fan capable of being operated at many speeds over one or more ranges of speeds. In other embodiments, the indoor fan 110 may be configured as a multiple speed fan capable of being operated at a plurality of operating speeds by selectively electrically powering different ones of multiple electromagnetic windings of a motor of the indoor fan 110. In yet other embodiments, the indoor fan 110 may be a single speed fan. While illustrated and described as a single indoor fan 110, a plurality of fans may be present in any system, and each of the fans may be the same or different than any of the other fans.

In an embodiment, the indoor metering device 112 is an electronically controlled motor driven electronic expansion valve (EEV). In alternative embodiments, the indoor metering device 112 may comprise a thermostatic expansion valve, a capillary tube assembly, and/or any other suitable metering device. The indoor metering device 112 may comprise and/or be associated with a refrigerant check valve and/or refrigerant bypass for use when a direction of refrigerant flow through the indoor metering device 112 is such that the indoor metering device 112 is not intended to meter or otherwise substantially restrict flow of the refrigerant through the indoor metering device 112.

Outdoor unit 104 generally comprises an outdoor heat exchanger 114, a compressor 116, an outdoor fan 118, an outdoor metering device 120, and a reversing valve 122. In an embodiment, outdoor heat exchanger 114 is a spine fin heat exchanger configured to allow heat exchange between refrigerant carried within internal passages of the outdoor heat exchanger 114 and fluids that contact the outdoor heat exchanger 114 but that are kept segregated from the refrigerant. In other embodiments, outdoor heat exchanger 114 may comprise a plate fin heat exchanger, a microchannel heat exchanger, or any other suitable type of heat exchanger.

In an embodiment, the compressor 116 is a multiple speed scroll type compressor configured to selectively pump refrigerant at a plurality of mass flow rates. In alternative embodiments, the compressor 116 may comprise a modulating compressor capable of operation over one or more speed ranges, a reciprocating type compressor, a single speed compressor, and/or any other suitable refrigerant compressor and/or refrigerant pump.

In an embodiment, the outdoor fan 118 is an axial fan comprising a fan blade assembly and fan motor configured to selectively rotate the fan blade assembly. In other embodiments, the outdoor fan 118 may comprise a mixed-flow fan, a centrifugal blower, and/or any other suitable type of fan and/or blower. The outdoor fan 118 is configured as a modulating and/or variable speed fan capable of being operated at many speeds over one or more ranges of speeds. In other embodiments, the outdoor fan 118 may be configured as a multiple speed fan capable of being operated at a plurality of operating speeds by selectively electrically powering different ones of multiple electromagnetic windings of a motor of the outdoor fan 118. In yet other embodiments, the outdoor fan 118 may be a single speed fan. While illustrated and described as a single outdoor fan 118, a plurality of outdoor fans may be present in any system, and each of the fans may be the same or different than any of the other fans.

In an embodiment, the outdoor metering device 120 is a thermostatic expansion valve. In alternative embodiments, the outdoor metering device 120 may comprise an electronically controlled motor driven EEV similar to indoor metering device 112, a capillary tube assembly, and/or any other suitable metering device. The outdoor metering device 120 may comprise and/or be associated with a refrigerant check valve and/or refrigerant bypass for use when a direction of refrigerant flow through the outdoor metering device 120 is such that the outdoor metering device 120 is not intended to meter or otherwise substantially restrict flow of the refrigerant through the outdoor metering device 120.

In an embodiment, the reversing valve 122 is a so-called four-way reversing valve. The reversing valve 122 may be selectively controlled to alter a flow path of refrigerant in the HVAC system 100 as described in greater detail below. The reversing valve 122 may comprise an electrical solenoid or other device configured to selectively move a component of the reversing valve 122 between operational positions.

In an embodiment, the system controller 106 may generally comprise a touchscreen interface for displaying information and for receiving user inputs. The system controller 106 may display information related to the operation of the HVAC system 100 and may receive user inputs related to operation of the HVAC system 100. However, the system controller 106 may further be operable to display information and receive user inputs tangentially and/or unrelated to operation of the HVAC system 100. In some embodiments, the system controller 106 may not comprise a display and may derive all information from inputs from remote sensors and remote configuration tools. In some embodiments, the system controller 106 may comprise a temperature sensor and may further be configured to control heating and/or cooling of zones associated with the HVAC system 100. In some embodiments, the system controller 106 may be configured as a thermostat for controlling supply of conditioned air to zones associated with the HVAC system 100. Additionally, in some embodiments, the system controller 106 may also be configured to control operation of the dehumidifier 150. In some embodiments, the system controller 106 may control operation of the dehumidifier 150 to adjust and/or control a humidity of the circulating air of HVAC system 100 in response to a target humidity selected via the system controller 106.

In some embodiments, the system controller 106 may also selectively communicate with an indoor controller 124 of the indoor unit 102, with an outdoor controller 126 of the outdoor unit 104, and/or with other components of the HVAC system 100. In some embodiments, the system controller 106 may be configured for selective bidirectional communication over a communication bus 128. In some embodiments, portions of the communication bus 128 may comprise a three-wire connection suitable for communicating messages between the system controller 106 and one or more of the HVAC system 100 components configured for interfacing with the communication bus 128. Still further, the system controller 106 may be configured to selectively communicate with HVAC system 100 components and/or any other device 130 via a communication network 132. In some embodiments, the communication network 132 may comprise a telephone network, and the other device 130 may comprise a telephone. In some embodiments, the communication network 132 may comprise the Internet, and the other device 130 may comprise a smartphone and/or other Internet-enabled mobile telecommunication device. In other embodiments, the communication network 132 may also comprise a remote server.

The indoor controller 124 may be carried by the indoor unit 102 and may be configured to receive information inputs, transmit information outputs, and otherwise communicate with the system controller 106, the outdoor controller 126, and/or any other device 130 via the communication bus 128 and/or any other suitable medium of communication. In some embodiments, the indoor controller 124 may be configured to communicate with an indoor personality module 134 that may comprise information related to the identification and/or operation of the indoor unit 102. In some embodiments, the indoor controller 124 may be configured to receive information related to a speed of the indoor fan 110, transmit a control output to an electric heat relay, transmit information regarding an indoor fan 110 volumetric flow-rate, communicate with and/or otherwise affect control over an air cleaner 136, and communicate with an indoor EEV controller 138. In some embodiments, the indoor controller 124 may be configured to communicate with an indoor fan controller 142 and/or otherwise affect control over operation of the indoor fan 110. In some embodiments, the indoor personality module 134 may comprise information related to the identification and/or operation of the indoor unit 102 and/or a position of the outdoor metering device 120. Additionally, in some embodiments, the indoor controller 124 may also be configured to control operation of the dehumidifier 150. In some embodiments, the indoor controller 124 may control operation of the dehumidifier 150 to adjust and/or control a humidity of the circulating air of HVAC system 100 in response to a target humidity selected via the system controller 106.

In some embodiments, the indoor EEV controller 138 may be configured to receive information regarding temperatures and/or pressures of the refrigerant in the indoor unit 102. More specifically, the indoor EEV controller 138 may be configured to receive information regarding temperatures and pressures of refrigerant entering, exiting, and/or within the indoor heat exchanger 108. Further, the indoor EEV controller 138 may be configured to communicate with the indoor metering device 112 and/or otherwise affect control over the indoor metering device 112. The indoor EEV controller 138 may also be configured to communicate with the outdoor metering device 120 and/or otherwise affect control over the outdoor metering device 120.

The outdoor controller 126 may be carried by the outdoor unit 104 and may be configured to receive information inputs, transmit information outputs, and otherwise communicate with the system controller 106, the indoor controller 124, and/or any other device 130 via the communication bus 128 and/or any other suitable medium of communication. In some embodiments, the outdoor controller 126 may be configured to communicate with an outdoor personality module 140 that may comprise information related to the identification and/or operation of the outdoor unit 104. In some embodiments, the outdoor controller 126 may be configured to receive information related to an ambient temperature associated with the outdoor unit 104, information related to a temperature of the outdoor heat exchanger 114, and/or information related to refrigerant temperatures and/or pressures of refrigerant entering, exiting, and/or within the outdoor heat exchanger 114 and/or the compressor 116. In some embodiments, the outdoor controller 126 may be configured to transmit information related to monitoring, communicating with, and/or otherwise affecting control over the outdoor fan 118, a compressor sump heater, a solenoid of the reversing valve 122, a relay associated with adjusting and/or monitoring a refrigerant charge of the HVAC system 100, a position of the indoor metering device 112, and/or a position of the outdoor metering device 120. The outdoor controller 126 may further be configured to communicate with a compressor drive controller 144 that is configured to electrically power and/or control the compressor 116.

The HVAC system 100 is shown configured for operating in a so-called cooling mode in which heat is absorbed by refrigerant at the indoor heat exchanger 108 and heat is rejected from the refrigerant at the outdoor heat exchanger 114. In some embodiments, the compressor 116 may be operated to compress refrigerant and pump the relatively high temperature and high pressure compressed refrigerant from the compressor 116 to the outdoor heat exchanger 114 through the reversing valve 122 and to the outdoor heat exchanger 114. As the refrigerant is passed through the outdoor heat exchanger 114, the outdoor fan 118 may be operated to move air into contact with the outdoor heat exchanger 114, thereby transferring heat from the refrigerant to the air surrounding the outdoor heat exchanger 114. The refrigerant may primarily comprise liquid phase refrigerant and the refrigerant may flow from the outdoor heat exchanger 114 to the indoor metering device 112 through and/or around the outdoor metering device 120 which does not substantially impede flow of the refrigerant in the cooling mode. The indoor metering device 112 may meter passage of the refrigerant through the indoor metering device 112 so that the refrigerant downstream of the indoor metering device 112 is at a lower pressure than the refrigerant upstream of the indoor metering device 112. The pressure differential across the indoor metering device 112 allows the refrigerant downstream of the indoor metering device 112 to expand and/or at least partially convert to a two-phase (vapor and gas) mixture. The two phase refrigerant may enter the indoor heat exchanger 108. As the refrigerant is passed through the indoor heat exchanger 108, the indoor fan 110 may be operated to move air into contact with the indoor heat exchanger 108, thereby transferring heat to the refrigerant from the air surrounding the indoor heat exchanger 108, and causing evaporation of the liquid portion of the two phase mixture. The refrigerant may thereafter re-enter the compressor 116 after passing through the reversing valve 122.

To operate the HVAC system 100 in the so-called heating mode, the reversing valve 122 may be controlled to alter the flow path of the refrigerant, the indoor metering device 112 may be disabled and/or bypassed, and the outdoor metering device 120 may be enabled. In the heating mode, refrigerant may flow from the compressor 116 to the indoor heat exchanger 108 through the reversing valve 122, the refrigerant may be substantially unaffected by the indoor metering device 112, the refrigerant may experience a pressure differential across the outdoor metering device 120, the refrigerant may pass through the outdoor heat exchanger 114, and the refrigerant may reenter the compressor 116 after passing through the reversing valve 122. Most generally, operation of the HVAC system 100 in the heating mode reverses the roles of the indoor heat exchanger 108 and the outdoor heat exchanger 114 as compared to their operation in the cooling mode.

Referring now to FIG. 2, a schematic diagram of an air circulation path 200 of the HVAC system 100 of FIG. 1 is shown according to an embodiment of the disclosure. The HVAC system 100 of FIG. 1 may generally be configured to circulate and/or condition air of a plurality of zones 202, 204, 206 of a structure 201. It will be appreciated that while three zones 202, 204, 206 are shown, any number of zones may be present in the structure 201. The air circulation path 200 of the HVAC system 100 may generally comprise a first zone supply duct 208, a second zone supply duct 210, a third zone supply duct 212, a first zone return duct 214, a second zone return duct 216, a third zone return duct 218, a main return duct 220, a main supply duct 222, a plurality of zone dampers 224, and an indoor unit 102 comprising an indoor fan 110. In addition to the components of HVAC system 100 described above, in this embodiment, each HVAC system 100 further comprises a dehumidifier 150 configured to adjust and/or control a humidity of the circulating air of HVAC system 100.

Additionally, the HVAC system 100 may further comprise a zone thermostat 158 and a zone sensor 160. In some embodiments, a zone thermostat 158 may communicate with the system controller 106 and may allow a user to control a temperature setting, a humidity setting, and/or other environmental setting for the zone 202, 204, 206 in which the zone thermostat 158 is located. Further, the zone thermostat 158 may communicate with the system controller 106 to provide temperature, humidity, and/or other environmental feedback regarding the zone 202, 204, 206 in which the zone thermostat 158 is located. In some embodiments, a zone sensor 160 may also communicate with the system controller 106 to provide temperature, humidity, and/or other environmental feedback regarding the zone 202, 204, 206 in which the zone sensor 160 is located.

The system controller 106 may be configured for bidirectional communication with any zone thermostat 158 and/or zone sensor 160 so that a user may, using the system controller 106, monitor and/or control any of the HVAC system 100 components regardless of which zones 202, 204, 206 the zone thermostat 158 and/or zone sensor 160 may be associated. Further, each system controller 106, each zone thermostat 158, and each zone sensor 160 may comprise a temperature sensor and/or a humidity sensor. As such, it will be appreciated that structure 201 is equipped with a plurality of temperature sensors and/or humidity sensors in the plurality of different zones 202, 204, 206. In some embodiments, a user may effectively select which of the plurality of temperature sensors and/or humidity sensors is used to control operation of the HVAC system 100. Thus, when at least one of the system controller 106, the zone thermostat 158, and the zone sensor 160 determines that a temperature and/or humidity of an associated zone has fallen outside either the temperature setting or the humidity setting, respectively, the system controller 106 may operate the HVAC system 100 in either the cooling mode or the heating mode to provide temperature conditioned air to at least one of the zones 202, 204, 206.

In operation, the indoor fan 110 may be configured to generate an airflow through the indoor unit 102 to deliver temperature conditioned air from an air supply opening in the indoor unit 102, through the main supply duct 222, and to each of the plurality of zones 202, 204, 206 through each of the first zone supply duct 208, the second zone supply duct 210, and the third zone supply duct 212, respectively. Additionally, each of the first zone supply duct 208, the second zone supply duct 210, and the third zone supply duct 212 may comprise a zone damper 224 that regulates the airflow to each of the zones 202, 204, 206. In some embodiments, the zone dampers 224 may regulate the flow to each zone 202, 204, 206 in response to a temperature or humidity sensed by at least one temperature sensor and/or humidity sensor carried by at least one of the system controller 106, the zone thermostat 158, and the zone sensor 160.

Air from each zone 202, 204, 206 may return to the main return duct 220 through each of the first zone return duct 214, the second zone return duct 216, and the third zone return duct 218. From the main return duct 220, air may return to the indoor unit 102 through an air return opening in the indoor unit 102. Air entering the indoor unit 102 through the air return opening may then be conditioned for delivery to each of the plurality of zones 202, 204, 206 as described above. Circulation of the air in this manner may continue repetitively until the temperature and/or humidity of the air within the zones 202, 204, 206 conforms to a target temperature and/or a target humidity as required by at least one of the system controller 106, the zone thermostat 158, and/or the zone sensor 160.

Furthermore, it will be appreciated that the dehumidifier 150 is disposed and/or installed in the main supply duct 222 of the air circulation path 200 of HVAC system 100 such that substantially all of the entirety of the airflow delivered to each of the plurality of zones 202, 204, 206 through the main supply duct 222 passes through the dehumidifier 150 to provide “whole-house” dehumidification to the plurality of zones 202, 204, 206 of the structure 201. By disposing the dehumidifier 150 in the main supply duct 222 of the air circulation path 200, dehumidification of the temperature conditioned airflow occurs after the airflow exits the air supply opening of the indoor unit 102. Additionally, the need for a secondary fan installed in the dehumidifier 150 is eliminated, since the air flow through the dehumidifier 150 is generated and/or controlled by the indoor fan 110 of the indoor unit 102. Accordingly, it will be appreciated that all of the airflow through the dehumidifier 150 is controlled by the indoor fan 110.

Still further, when only dehumidification is needed in the zones 202, 204, 206 of the structure 201, the indoor unit 102 may not be operated to provide cooling and/or heating to the airflow moving through the indoor unit 102. However, the indoor fan 110 may be operated to pass the airflow through the dehumidifier 150 to dehumidify the airflow and pass air to at least one of the zones 202, 204, 206, while the remainder of the components of the indoor unit 102 remains inactive. Accordingly, any of the system controller 106, zone thermostat 158, and the zone sensor 160 comprising a humidity sensor may determine a need for dehumidification, and in response to the need for dehumidification, the system controller 106 may operate the indoor fan 110 and the dehumidifier 150 to generate and dehumidify, respectively, an airflow supplied to the zones 202, 204, 206. Furthermore, zone dampers 224 may be operated to control the flow to zones 202, 204, 206 based on the demand for dehumidification in any one of the zones 202, 204, 206. Additionally, to prevent an excess pressure drop across the dehumidifier 150, it will be appreciated that the dehumidifier 150 comprises a cross sectional area of a flowpath through the dehumidifier 150 that is substantially similar and/or equal to the cross sectional area of the main supply duct 222 in which the dehumidifier 150 is disposed. However, in other embodiments, the dehumidifier 150 may comprise a cross sectional area that is greater than the cross sectional area of the main supply duct 222.

Referring now to FIG. 3 is a schematic diagram of an air circulation path 300 of the HVAC system 100 of FIG. 1 is shown according to another embodiment of the disclosure. It will be appreciated that the air circulation path 300 is substantially similar to the air circulation path 200 of FIG. 2, and the HVAC system 100 may be operated to condition air through the air circulation path 300 in a substantially similar manner as air circulation path 200 of FIG. 2. However, the dehumidifier 150 of the air circulation path 300 is disposed and/or installed in the main return duct 220 of the air circulation path 300 of HVAC system 100 such that substantially all of the entirety of the airflow from each of the plurality of zones 202, 204, 206 that is passed to the indoor unit 102 passes through the dehumidifier 150 to provide “whole-house” dehumidification to the plurality of zones 202, 204, 206 of the structure 201. By disposing the dehumidifier 150 in the main return duct 220 of the air circulation path 300, dehumidification of the temperature conditioned airflow occurs prior to the airflow entering the air return opening of the indoor unit 102. Additionally, similar to the air circulation path 200 in FIG. 2, the need for a secondary fan installed in the dehumidifier 150 is eliminated, since the air flow through the dehumidifier 150 is generated and/or controlled by the indoor fan 110 of the indoor unit 102. Accordingly, it will be appreciated that all of the airflow through the dehumidifier 150 is controlled by the indoor fan 110. Additionally, to prevent an excess pressure drop across the dehumidifier 150, it will be appreciated that the dehumidifier 150 comprises a cross sectional area of a flowpath through the dehumidifier 150 that is substantially similar and/or equal to the main return duct 220 in which the dehumidifier 150 is disposed. However, in other embodiments, the dehumidifier 150 may comprise a cross sectional area that is greater than the cross sectional area of the main return duct 220.

Referring now to FIG. 4 is a schematic diagram of an air circulation path 400 of the HVAC system 100 of FIG. 1 is shown according to yet another embodiment of the disclosure. It will be appreciated that the air circulation path 400 is substantially similar to the air circulation paths 200, 300 of FIGS. 2 and 3, and the HVAC system 100 may be operated to condition air through the air circulation path 400 in a substantially similar manner as air circulation paths 200, 300 of FIGS. 2 and 3. However, the dehumidifier 150 of the air circulation path 300 is disposed and/or installed in the indoor unit 102 of HVAC system 100 such that substantially all of the entirety of the airflow from each of the plurality of zones 202, 204, 206 that is passed through the indoor unit 102 passes through the dehumidifier 150 to provide “whole-house” dehumidification to the plurality of zones 202, 204, 206 of the structure 201. By disposing the dehumidifier 150 in the indoor unit 102 of the air circulation path 400 of HVAC system 100, dehumidification of the temperature conditioned airflow occurs within the indoor unit 102. Additionally, similar to the air circulation paths 200, 300 in FIGS. 2 and 3, the need for a secondary fan installed in the dehumidifier 150 is eliminated, since the air flow through the dehumidifier 150 is generated and/or controlled by the indoor fan 110 of the indoor unit 102. Accordingly, it will be appreciated that all of the airflow through the dehumidifier 150 is controlled by the indoor fan 110.

Accordingly, with the dehumidifier 150 installed in the indoor unit 102, the dehumidifier 150 may be installed in a vacant section of the indoor unit 102 and may be disposed upstream or downstream with respect to other components of the indoor unit 102 (i.e. indoor heat exchanger 108, indoor fan 110). The dehumidifier 150 may also be configured to fit in an existing cabinet section of the indoor unit 102. As such, in some embodiments, the dehumidifier 150 may be configured to fit in and be housed within an air filtration element cabinet section. In some embodiments, the indoor unit 102 may be a “blow through” type air handling unit with the indoor fan 110 disposed near the air return opening of the indoor unit 102 and the dehumidifier 150 disposed downstream of the indoor fan 110 within the indoor unit 102. Alternatively, in other embodiments, the indoor unit 102 may be a “pull through” type air handling unit with the indoor fan 110 disposed near the air supply opening of the indoor unit 102 and the dehumidifier 150 disposed upstream of the indoor fan 110 within the indoor unit 102.

Additionally, to prevent an excess pressure drop across the dehumidifier 150, it will be appreciated that the dehumidifier 150 comprises a cross sectional area of a flowpath through the dehumidifier 150 that is substantially similar and/or equal to the cross sectional area of at least a portion of the indoor unit 102 in which the dehumidifier 150 is disposed. However, in other embodiments, the dehumidifier 150 may comprise a cross sectional area that is substantially similar and/or equal to the cross sectional area of adjacent sections of the indoor unit 102. Furthermore, it will be appreciated that the indoor unit 102 also comprises a drain pan for which condensate from the indoor heat exchanger 108 may drain. Thus, in some embodiments, the dehumidifier 150 may share at least a portion of the drain pan for the indoor heat exchanger 108. Accordingly, condensate from each of the indoor heat exchanger 108 and at least one heat exchanger of the dehumidifier 150 may drain into the drain pan of the indoor unit 102.

It should be noted that although embodiments and examples are provided in the context of cooling and/or dehumidification through air circulation paths 200, 300, 400, the HVAC system 100 and/or the dehumidifier 150 may also be configured to operate in a heating mode and/or a humidifying mode (addition of humidity), respectively, in any of the above-mentioned embodiments. Further, while the HVAC systems 100 is shown as a so-called split system comprising an indoor unit 102 located separately from the outdoor unit 104, alternative embodiments of an HVAC system 100 may comprise a so-called package system in which one or more of the components of the indoor unit 102 and one or more of the components of the outdoor unit 104 are carried together in a common housing or package.

Referring now to FIG. 5, a schematic diagram of a dehumidifier 500 is shown according to an embodiment of the disclosure. The dehumidifier 500 comprises a vapor-compression dehumidification system and may be substantially similar to and used in place of dehumidifier 150 in FIGS. 1-4. The dehumidifier 500 comprises an enclosure 502 configured to house an evaporator 504 upstream from a condenser 506 with respect to an airflow 522 through the dehumidifier 500. In some embodiments, the evaporator 504 and/or the condenser 506 may comprise plate-fin heat exchanger, tube-fin heat exchangers, and/or spine-fin heat exchangers configured to exchange heat between a fluid and/or refrigerant within the internal passages of the evaporator 504 and/or the condenser 506 and an airflow 522 generated by the indoor fan 110. The dehumidifier 500 also comprises a compressor 508 configured to perform substantially similar functions to compressor 116 of FIG. 1 and an expansion device 510 configured to perform substantially similar functions to expansion devices 112, 120 of FIG. 1. While the compressor 508 and the expansion device 510 are shown outside of the enclosure 502, in some embodiments, the compressor 508 and/or the expansion device 510 may be disposed within the enclosure 502.

Additionally, each of the evaporator 504, condenser 506, compressor 508, and the expansion device 510 may be connected in fluid communication to form a fluid circuit by suction line 514, compressor discharge line 516, condenser discharge line 518, and liquid line 520. Furthermore, the dehumidifier 500 and/or the evaporator 504 may comprise a drain 512 from which condensate from the evaporator 504 may be collected and/or carried away from the dehumidifier 500. In embodiments where the dehumidifier 500 is disposed in the indoor unit 102, such as the air circulation path 400 of FIG. 4, the drain 512 may comprise a common drain with indoor heat exchanger 108 of the indoor unit 102 of HVAC system 100.

In this embodiment, the airflow 522 generated by the indoor fan 110 that passes through the dehumidifier 500 passes through each of the evaporator 504 and the condenser 506, such that no portion of the airflow 522 bypasses either the evaporator 504 or the condenser 506. The evaporator 504 is disposed upstream from the condenser 506 with respect to the airflow 522 through the dehumidifier 500. Accordingly, the evaporator 504 is configured to cool and dehumidify the airflow 522, while the condenser 506 is configured to reheat the airflow 522. In some embodiments, the evaporator 504 may comprise fewer fins and/or tubes than a conventional evaporator to prevent too high of a pressure drop through the dehumidifier 500 since all of the airflow 522 passes through the evaporator 504. Additionally, by passing all of the airflow 522 generated by the indoor fan 110 through the dehumidifier 500, the dehumidifier 500 provides dehumidification of the airflow 522 at efficiencies of at least about 40% higher to at least about 110% higher than current commercially available dehumidifiers.

Referring now to FIG. 6, a schematic diagram of a dehumidifier 600 is shown according to another embodiment of the disclosure. The dehumidifier 600 comprises a vapor-compression dehumidification system and may be substantially similar to and used in place of dehumidifier 150 in FIGS. 1-4. Dehumidifier 600 may also be substantially similar to dehumidifier 500 in FIG. 5. As such, dehumidifier 600 comprises an enclosure 602, an evaporator 604 upstream from a condenser 606 with respect to an airflow 622 through the dehumidifier 600, a compressor 608, an expansion device 610, a drain 612, a suction line 614, a compressor discharge line 616, a condenser discharge line 618, and a liquid line 620 that are substantially similar to the enclosure 502, the evaporator 504, the condenser 506, the airflow 522, the compressor 508, the expansion device 510, the drain 512, the suction line 514, the compressor discharge line 516, the condenser discharge line 518, and the liquid line 520 of dehumidifier 500 of FIG. 5.

However, in this embodiment, the dehumidifier 600 comprises an evaporator bypass section 624 through which at least a portion of the airflow 622 generated by the indoor fan 110 may bypass the evaporator 604, while the entire airflow 522 passes through the condenser 606. As such, only a portion of the airflow 522 that passes through the evaporator 604 may be cooled and/or dehumidified by the evaporator 604, while the entire airflow 522 may be heated and/or reheated by the condenser 606. The evaporator bypass section 624 may be located above a top end of the evaporator 604 as shown in FIG. 6. Alternatively, in some embodiments, the evaporator bypass section 624 may be located below a bottom end of the evaporator 604. However, in other embodiments, the dehumidifier 600 may comprise a plurality of evaporator bypass sections 624, such that a first evaporator bypass section 624 may be located above the top end of the evaporator 604, and a second evaporator bypass section 624 may be located below the bottom end of the evaporator 604. By providing an evaporator bypass section 624, the evaporator 604 may comprise a smaller size and/or a smaller capacity than that of the condenser 606 to accommodate the evaporator bypass section(s) 624. Additionally, by bypassing the evaporator 604 with a portion of the airflow 522, a lower pressure drop may occur through the dehumidifier 600 as compared to conventional dehumidifiers. Still further, the dehumidifier 600 provides dehumidification of the airflow 622 at efficiencies of at least about 40% higher to at least about 110% higher than current commercially available dehumidifiers.

Referring now to FIG. 7, a flowchart of a method 700 of operating an HVAC system 100 is shown according to an embodiment of the disclosure. The method 700 may begin at block 702 by providing a dehumidifier in an HVAC system 100. In some embodiments, a dehumidifier 150, 500, 600 may be provided in the HVAC system 100. Additionally, in some embodiments, the dehumidifier 150, 500, 600 may be disposed in at least one of a main supply duct 222, a main return duct 220, and an indoor unit 102 in an air circulation path 200, 300, 400, respectively, in the HVAC system 100. The method 700 may continue at block 704 by generating an airflow 522, 622 through the dehumidifier. In some embodiments, the airflow 522, 622 may be generated solely by the indoor fan 110 of indoor unit 102 of the HVAC system 100. The method 700 may continue at block 706 by reducing the humidity of the airflow 522, 622. In some embodiments, reducing the humidity of the airflow 522, 622 may be accomplished by passing the airflow 522, 622 through the dehumidifier 150, 500, 600. However, in some embodiments, reducing the humidity of the airflow 522, 622 may be accomplished by passing substantially the entirety of the airflow 522, 622 through an evaporator 504 of the dehumidifier 500. However, in yet other embodiments, reducing the humidity of the airflow 522, 622 may be accomplished by passing at least a portion of the airflow 522, 622 through an evaporator 604 of the dehumidifier 600 and further passing at least a portion of the airflow 522, 622 through an evaporator bypass section 624. The method 700 may conclude at block 708 by delivering the reduced humidity airflow 522, 622 to at least one zone 202, 204, 206 of a structure 201 conditioned by the HVAC system 100. In some embodiments, delivering the reduced humidity airflow 522, 622 to at least one zone 202, 204, 206 conditioned by the HVAC system 100 may be accomplished by passing the reduced humidity airflow through a main supply duct 222 and/or at least one zone supply duct 208, 210, 212 of at least one of the air circulation paths 200, 300, 400 of HVAC system 100.

At least one embodiment is disclosed and variations, combinations, and/or modifications of the embodiment(s) and/or features of the embodiment(s) made by a person having ordinary skill in the art are within the scope of the disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of the disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, R₁, and an upper limit, R_u, is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=R₁+k*(R_u−R₁), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . , 50 percent, 51 percent, 52 percent, . . . , 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Unless otherwise stated, the term “about” shall mean plus or minus 10 percent of the subsequent value. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Use of the term “optionally” with respect to any element of a claim means that the element is required, or alternatively, the element is not required, both alternatives being within the scope of the claim. Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of Accordingly, the scope of protection is not limited by the description set out above but is defined by the claims that follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present invention.

Dehumidifier for High Airflow Rate Systems

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